Modular rack system and components therefor

ABSTRACT

Embodiments of the invention may encompass a container storage system having a modular storage rack including framing elements each having a locking component of at least one end thereof and a counterpart locking component on another end; each locking element being engagable with each other; and wherein the storage rack is assembled to maximize storage capacity within the shipping container. It may also include a modular array having at least one elongated framing element with at least one key on at least one end thereof having an elongated rotatable member having at least one flange extending radially therefrom; at least one other elongated framing element having at least one opening being shaped to receive the key; wherein the framing elements are arranged to form the array and the key and the opening are used to engage the framing elements by inserting the key into the opening and rotating the key.

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/794,183, filed Apr. 21, 2006.

BACKGROUND

The invention relates to the field of racks for shipping and storing industrial products. More particularly, the invention relates to modular shipping and storage racks and components therefor.

As is well known to those working in the shipping and storage industries, there is a veritable plethora of rack systems used for the transport and/or storage of countless numbers of items ranging from fasteners, to automobiles, to heavy industrial equipment and so forth. Generally, such rack systems are designed for a particular purpose, such as the transport or storage of a particular type of item, be it tools, gears, bumpers, wheels, etc. As a rule, a rack system designed for a particular purpose is not readily adaptable for another purpose. For example, rack systems optimized for storage make poor shipping containers, as they are generally built to take primarily downward loads. In addition, such systems ordinarily provide little protection to the merchandise from the jolts and jarring that are inherent to stevedoring operations. On the other hand, rack systems optimized for shipment of merchandise generally make poor storage devices. To the applicant's knowledge, the design of rack systems which accommodate a wide range of products of varying size in both shipping and storage functions is still in its infancy.

What is needed is a modular rack system, the configuration of which can be readily modified to accept a variety of merchandise, and which can be ganged, expanded, contracted, or fitted with accessories, as needed. Additional desirable qualities would be that the modular rack system, when assembled and loaded, be easily moved by forklift and readily fitted with lift cables, and that when no longer needed for storage or transport purposes, it be easily disassemblable, stowable, and transportable.

Further, a significant problem in shipping is the need, in a more security conscious world, of inspecting or testing articles in shipping containers entering or leaving a county's ports. Generally, articles are packed densely into shipping containers to maximize the return on the expense of renting the container. These articles are typically stacked box on box, without any rack or internal storage container. Consequently, it is very time consuming and expense to inspect or test articles in these containers, due to the need to remove the articles box by box for inspection. A further advantage of the invention would be its adaptation for use within existing shipping containers, allowing ease of access to merchandise for inspection or testing, without the need to unpack the container.

SUMMARY OF THE INVENTION

Embodiments of the invention may encompass a shipping container storage system having a modular storage rack that includes a plurality of framing elements, each of the framing elements having a locking component of at least one end thereof and a counterpart locking component on another end thereof, each of the locking component and the counterpart locking element being engagable with each other to connect said framing elements together; and wherein the modular storage rack is assembled in a configuration to maximize storage capacity within the shipping container.

A further embodiment of the invention may include a modular array having at least one elongated framing element; at least one key on at least one ends of the framing element, the key having an elongated rotatable member and at least one flange extending radially from the elongated rotatable member; at least one other elongated framing element; at least one opening on the other elongated framing element, the opening being shaped to receive the key; wherein the framing elements are arranged to form the array and the key and the opening are used to engage the framing elements by inserting the key into the opening and rotating the key.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention, together with other objects, features and advantages, reference should be made to the following detailed description which should be read in conjunction with the following figures wherein like numerals represent like parts.

FIG. 1 is an isometric view of a modular rack system constructed from a plurality of coupler blocks, beams, and shock-absorbing feet, in accordance with the invention;

FIG. 2 is an isometric view of a complex modular rack array constructed from multiples of the basic components depicted in FIG. 1;

FIG. 3 is an isometric view of a coupler block, a plurality of which are used to construct the modular rack system;

FIG. 4 is a top plan view of a coupler block;

FIG. 5 is a cross-sectional view of a coupler block taken along line 5-5 of FIG. 4;

FIG. 6 is an isometric view of a beam;

FIG. 7 is an end view of a beam perpendicular to its longitudinal axis;

FIG. 8 is an isometric view of a shock-absorbing foot;

FIG. 9 is a side elevational phantom view of a shock-absorbing foot;

FIG. 10 is an isometric view of drawer guides which can be mounted within the modular rack system;

FIG. 11 is a close-up view of the guide-to-rack attachment area identified in FIG. 10;

FIG. 12 is a side elevational view of a modular rack system following the installation of drawer guides and a drawer;

FIG. 13 is a side elevational view of a modular rack system having laterally-mounted shock-absorbing feet;

FIG. 14 is an isometric view of two modular rack systems, one of which has been stacked on top of the other;

FIG. 15 is a diagram of a container rack system in accordance with aspects of the invention.

FIG. 16 is a diagram of a further embodiment of a connector system in accordance with aspects of the invention.

FIG. 17 is a diagram of another further embodiment of a connector system in accordance with aspects of the invention.

DETAILED DESCRIPTION

For simplicity and ease of explanation, the invention will be described herein in connection with various exemplary embodiments thereof. Those skilled in the art will recognize, however, that the features and advantages of the invention may be implemented in a variety of configurations. It is to be understood, therefore, that the embodiments described herein are presented by way of illustration, not of limitation.

At the outset, and as shown in the drawing and in particular FIG. 1, it is to be noted that the new modular rack system, as depicted in an example of a rack array generally denoted 10, may incorporate multiple units of two principal components: a coupler block 11, and a beam generally denoted 12. It will be noted that the beams are labeled 12A through 12D, as they may be of different lengths or fitted with additional accessories. For example, although beams 12A and 12D may be of identical length, beams 12D may incorporate bracket,s which will be hereinafter described. Each coupler block 11 may be designed such that it has six cubically-arranged faces; 3, each face being equipped with an appropriately-sized aperture 14 for slidably receiving one end of a beam 12. The received end of beam 12 may be locked within the aperture by means of a retaining pin 15, which may be inserted within a pin insertion hole 16 in the coupler block, thereby also passing through a locking hole (not shown in this Figure) in the end of the received beam. Each of the six apertures 14 may have associated therewith a pin insertion hole 16 in the coupler block for receiving a retaining pin 15. The modular rack system also may incorporate multiple shock absorbing feet 17, each of which may be nestingly secured to a coupler block 11 positioned at each lowermost corner of the rack array 10. It will be noted that each of beams 12D may incorporate a pair of forklift stirrups 18, which provide not only correct positioning of lifting forks, but also prevent the array 10 from tipping during lifting. Such forklift stirrups 18 may be mounted with fasteners, slidably mounted within the T-shaped longitudinal grooves of the beam 12 (see the detailed description of FIG. 6), or may be welded to the beams 12.

It should be evident that a variety of rack array configurations may be formed by combining coupler blocks 11 and beams of various lengths 12 in a virtually limitless number of ways. FIG. 2, which depicts one such combination, includes forty-one coupler blocks 11, seventy-five beams 12, and six shock-absorbing feet 17. Although the rack array of FIG. 2 is only one possible combination of coupler blocks 11 and beams 12, it demonstrates the versatility of the new modular rack system.

Referring now to FIG. 3, certain features of the coupler block 11 that were described while referring to FIG. 1 are now more clearly visible. For example, three apertures 14A, 14B, and 14C of the six apertures (generally denoted 14) in coupler block 11 are visible, as are a pair of retaining pins 15A and 15B, which are shown inserted in their respective pin insertion holes 16 in the coupler block 11. The right-most pin 15B is also visible within aperture 14A. It will be noted that each retaining pin (generally denoted 15) may have a pull ring 31 attached thereto. The interior of each aperture 14 may incorporate four alignment guide rails 32 (one on each aperture wall 33), two of which are visible in aperture 14A, and one of which is visible in aperture 14C. The coupler blocks 11 may be cast as a single unit from a lightweight structural metal such as aluminum or magnesium, or it may be formed as a composite item, having a central connector assembly (not shown in its entirety in this Figure) formed, ideally, from a high-strength wear-resistant metal, that is insert molded within a durable body 34 which incorporates the apertures 14 and guide rails 32 and gives the coupler block 11 its general exterior shape.

The central connector assembly, which may be fabricated as a welded-up unit from a metal such as steel or titanium, may extend into each of the six apertures of the coupler block 11. If a coupler block is fabricated in such a manner, the square tube 35 visible in aperture 14A may be such an extension. If a coupler block 11 is cast or machined as a single unit, then the body 34 and the entire central connector assembly, which includes square tube 35, may simply be part of a single casting. In any case, each square tube extension 35 may have an anchoring hole 36 therethrough for receiving a retaining pin 15. This anchoring hole 36 may be aligned with the pin insertion hole 16 through the coupler block body 34.

The beams 12 of a rack system array may be tied to this central connector assembly. If the coupler block 11 is formed as a composite item, the coupler block body 34 may be formed from any suitable, durable material, such as a plastic, a lightweight metal such as aluminum or magnesium or alloys thereof, or the like. Useful plastic materials include ABS resins, epoxy resins, high-density polyethylene, polyalkylenes, polycarbonates, and polyurethanes used either alone or in combination with reinforcing high-tensile-strength fibers, such glass or graphite. When made of a moldable material, the coupler block body 34 may be formed by any suitable molding process known to the skilled artisan. It is to be understood that it is not the particular material or the method by which it is molded that is a critical factor, but rather that the body be formed from a suitable durable material. The coupler block body 34 may theoretically have any desired three-dimensional polygonal configuration (e.g., pyramidal, pentahedral, cubic, octahedral or decahedral). A cubic configuration permits rectangular rack arrays. As will be noted each of the six faces 13 of the coupler block body 34 may have a boss 37 which surrounds the aperture 14. The boss 37 imparts additional strength to the coupler block body 34 without a corresponding increase in total weight.

Referring now to FIG. 4, certain features of the coupler block are more clearly defined. For example, in this view, all four guide rails 32 within an aperture 14 are seen, as is a retaining pin insertion hole 16 (the longitudinal axis of which is perpendicular to the page), boss 37, and the square-cross-section tube 35. Also visible is a central threaded hole 41. The aperture 14 of each face may have a threaded hole 41.

Referring now to FIG. 5, this cross-sectional view is shown mainly to expose the central connector assembly 51 of a composite coupler block 11. This central connector assembly may be formed as a single piece of metal by casting or machining, or it may be welded-up from various components. Visible in this view are four square tube extensions 35A, 35B, 35C and 35D, which are associated with four of the six faces of the coupler block. In this view, tube extensions 35A, 35B, 35C and 35D have been sliced open. One of each pair of anchoring holes 36 in tube extensions 35A and 35B is visible in one wall of square tube extensions 35A and 35B, where as half of each anchoring hole 36 in the opposing walls of square tube extensions 35C and 35D are visible. It should be emphasized that the interior structure visible in a cross-section through any of the six faces will be essentially the same.

The welded-up central connector assembly 51 may be formed from hollow interior cube 52. One square tube extension 35 may be welded to each of the six faces of this interior cube 52. In the center of each region of a face of the interior cube 52 may be a threaded hole 41. The threaded holes 41 in opposing sides not only permit passage of a supporting cable through the center of the coupler block 11, but also provide a threaded anchor for a bolt which may be used to attach a shock-absorbing foot 18 to any of the six faces 13 of the coupler block 11. Each edge of the interior cube 52 may have a fin 54 welded thereto. The eight fins 54 (one for each edge of the cube) may be imbedded within the material from which the coupler block body 34 is cast, and assist in maintaining the welded-up central connector assembly 51 firmly anchored within the coupler block body 34.

Referring now to FIG. 6, certain features of the beam 12 which were previously alluded to are now clearly visible. For one embodiment of the invention, each beam 12 may be extruded from a light, high-strength metal such as aluminum, magnesium or an alloy thereof. Each beam 12 may be of more or less square cross-section, having chamfered edges 61 and a hollow core 62 which extends the entire length of the beam. As heretofore stated, each end of the beam 12 may incorporate a locking hole 63, both of which are now visible in this view. Each of the four sides of the beam may incorporate a T-shaped longitudinal groove 64, which, like the hollow core 62, may extend the entire length of the beam. Threaded fasteners 65, which are essentially bolts having a square or rectangular head sized to fit the groove 64, may be inserted within the groove and employed to removably mount protective covers, flooring, shelves, doors, hinges, and so forth on the beams 12. With the flooring and shelving so installed, merchandise may then be loaded on the modular rack array 10. Furthermore, by the disposition of suitable auxiliary components, it is possible to install drawers within a rack array. Such an installation is shown in FIGS. 10 and 11.

Referring now to FIG. 7, the substantially square cross section of a beam 12 is clearly evident. Each of the four T-shaped grooves 64 is clearly visible, as is the hollow central core 62.

Referring now to FIGS. 8, a shock-absorbing foot 18, which is generally of cubical shape, also has a recess 81T on the top thereof, which nestingly receives the face and boss of a coupler block.

Referring now to FIG. 9, an embodiment of the shock-absorbing foot 18 may be formed from a body 90 formed from flexible polymeric material, such as butyl or natural rubber (or a combination of the two) that may be reinforced in the sidewalls 91S and in the floor portion 91F, much like a vehicle tire, with high-tensile cord 92, such as nylon, kevlar, polyester, rayon, etc. The top recess 81T and a bottom recess 81B may be formed in the body. Each recess 81T or 81B may be sized to nestingly receive the face 13 and boss 37 of a coupler block 11. A generally inflexible insert 93 may be embedded within the flexible polymeric material of a roof portion 91R, central core portion 91C, and the bottom portion 91B of the foot 18. A compressible internal chamber 94 may be formed by the sidewalls 91S, the roof portion 91R, and the floor portions 91F of the foot 18.

A valve 95 may be incorporated in the foot 18, which allows the chamber 94 to be pressurized with air or some other appropriate gas to accommodate loads of varying weights. A hollow-core mounting bolt 96 may be used to secure the foot 18 to a coupler block 11. The internal chamber 94, particularly when inflated, defines a compressible shock absorber or bumper which not only protects an attached coupler block 11, but also protects the entire rack array 10 and the merchandise stored therein from excessive jarring and shock. In order to determine the shock loading to which the rack array 10 has been subjected during transit, loading and unloading, an electronic shock recorder may be installed on the rack assembly in any suitable position. It is to be appreciated that in assembling a rack, such as that disclosed in FIG. 1, that further stacking can be achieved and that a foot 18 can be disposed between adjacent vertical or horizontal associated coupler blocks 11 for heavier loads and for lateral impact. Also, a plurality of lugs can be nested together at any desired intersection. Interconnecting struts and lugs can also be used.

Referring now to both FIGS. 4, 6 and 9, as there is no blockage between threaded holes 41 of opposed faces, a cable may be threaded through a coupler block 11 via any opposed pair of threaded holes 41. As has been seen, each beam 12 has a hollow center, which permits a cable or lifting rod to be strung up through the hollowcore mounting bolt inserted within a shock-absorbing foot 18, through a coupler block 11, through the core of a beam 12, then through another coupler block, and so forth, until reaching the top of the rack array, where it may be utilized, in combination with other cables so positioned, to lift the rack array. A swedged-on cable end may be used to anchor the cable and also hold the foot 18 on the rack array.

It is to be appreciated that electronic tagging devices may be associated with the modular rack system for identification, inventory control and shipment routing. For example, one or more electronic modules may be attached to the rack system. A radio-frequency identification tag having rewritable on-board memory may be used for shipment identification, inventory control and shipment routing functions. A simpler electronic module might only provide a rewritable memory for storing an electronic inventory list and shipping manifest.

Referring now to FIG. 10, the modular rack array of FIG. 1 is shown with a pair of drawer guides 1001 installed between vertically-oriented beams 12D. As is seen in the close-up view of FIG. 11, the end of each drawer guide may have a pair of tabs 1101, each tab having a bolt hole by means of which the tab may be secured to a threaded fastener 65 inserted within the T-shaped groove 64 of the beams 12D. In the front elevational view of FIG. 12, a drawer 1201 having a handle 1202 is shown mounted on the drawer guides 1001. An electronic module 1203, which may provide at least some of the features described in the foregoing paragraph, is shown secured within an unused aperture 14 of a coupler block 11.

Referring now to FIG. 13, a pair of shock-absorbing feet 17 may be laterally mounted on the upper-most coupler blocks 11. The use of the shock-absorbing feet 17 in this manner protects the rack array and any merchandise stored therein from lateral shocks.

Referring now to FIG. 14, two rack arrays 10A and 10B are shown with rack array 10B being stacked on top of rack array 10A. In this case, the upper-most coupler blocks of the lower rack array 10A may be nested in the shock-absorbing feet mounted on the lower-most coupler blocks of the upper rack array 10B. The nesting feature maintains stacking alignment during transport of the rack arrays, even in the face of normal vertical and lateral forces that occur during shipment.

It should now be fully appreciated that the design of the coupler block 11 and longitudinal beams 12 enables the erection of a virtually limitless variety of rack arrays using multiple coupler blocks 11 and a plurality of beams 12 of desired lengths. In addition, the new modular rack system is ideally suited to computer-controlled “pick and place” robotic assembly. The modular rack system herein described also accommodates electronic monitoring of shock forces to which the system is subjected.

Further embodiments of the invention are illustrated in FIGS. 15 and 16. As previously noted, the inspection of goods coming into ports in containers is problematic in that it is time consuming (and unrealistic) to unpack entire containers to conduct random inspections. Embodiments of the invention provide a real solution to this significant security problem. The invention has the ability to provide access to the gross container, without the need to unpack the container. Embodiments of the invention may include sub-set racks that can be rolled in and out of the shipping containers.

As is clear from the above descriptions, the sub-set rack would not add substantial weight to the gross container wait. For example, the rack could be steel frame with aluminum side walls. Moreover, most container loads are filled to capacity based upon volume long before the maximum weight limit of the container is reached, allowing significant margin for any additional weight from the rack system of the invention.

An illustration of an embodiment of the invention along these lines is shown in FIG. 15. As shown in FIG. 15, the sub-set container rack may be configured as a segmented system that is shaped to fit within the space of the shipping container. One embodiment, for example, may include two separate racks, each of which has a top and a bottom segment. Thus, in a conventional twenty foot container, two racks measuring 8 ft.×8 ft.×10 ft. may be used, having a top and a bottom section. Alternatively, in a forty foot container, four such racks may be used as an example. Moveable/removeable shelves and side panels may be further included, providing easy access to various sections of the container cargo. Sub-containers, such as those having pull out drawers might also be used, again enabling local access to pieces of cargo without the need to unpack significant portions of the container.

In such an embodiment, or others, a further type of connector mechanism may be used. An example of this is illustrated in FIGS. 16 and 17. As shown in these figures, the connector mechanism may comprise a key based system, wherein an elongated rotatable element (substantially cylindrical, for example) having one or more flanges extending radially therefrom may be inserted into a portion of one frame element for joining two framing elements together. Each frame element may also have an end having a key and another end having an opening shaped appropriately to receive the key, making the framing elements somewhat interchangeable. The end of a frame element containing a key may be joined to the end of another framing element having a key opening. The key may be placed into the opening and then turned, thereby inhibiting the two sections from being separated as the flange sections of the key contact the surface of the framing element. The opening may also have inclined radial sidewalls, creating a compression type fitting.

The key may include a hole in the substantially cylindrical element, allowing a rod or other elongated abject to be inserted into the hole for rotating the key. In one embodiment, the framing element may have an opening across a face thereof to allow such bar to be inserted to the key.

The key may be mounted to the framing element, for example, using a mounting screw as illustrated. Of course, those of ordinary skill in the art that the key may be mounted using any number of conventional means and configurations. Also, those of ordinary skill in the art will appreciate that framing elements may also be connected at a corner or angle by including a key extending at an angle from the end or side of the framing element, and similarly an angled opening on another framing element.

Wheels or rollers may be included, along with a tow plate, allowing the racks to be wheeled in and out of the container. Lifting rails for forklifts, pallet jacks, etc. may also be included to the remove the racks in that manner.

An omni type coupler may also be incorporated, allowing elements to be coupled both horizontally and vertically in one or more directions.

In the above manner, embodiment of the invention may be used to solve the port embarkation inspection problem. The invention also allows faster packing of containers, as racks may even be preloaded at the factory or other source.

The embodiments that have been described herein, however, are but some of the several which utilize this invention and are set forth here by way of illustration but not of limitation. It is obvious that many other embodiments, which will be readily apparent to those skilled in the art, may be made without departing materially from the spirit and scope of the invention as defined in the appended claims. Changes and modifications to the system may be made without departing from the scope and spirit of the invention as hereinafter claimed. For example, other means for securing the beams to the coupler blocks may be employed. Similarly, other types of coupler blocks and beams which similarly cooperate may also be used. 

1. (canceled)
 2. A modular array, comprising: at least one elongated framing element; at least one key on at least one ends of said framing element, said key having an elongated rotatable member and at least one flange extending radially from said elongated rotatable member; at least one other elongated framing element; at least one opening on said other elongated framing element, said opening being shaped to receive said key; wherein said framing elements are arranged to form said array and said key and said opening are used to engage said framing elements by inserting said key into said opening and rotating said key.
 3. The modular array of claim 2, wherein said opening further comprises an inclined surface around at least a portion thereof, causing said flange to compress said framing elements together when said key is rotated.
 4. A shipping container storage system comprising: a modular storage rack comprising: at least one elongated framing element; at least one key on at least one ends of said framing element, said key having an elongated rotatable member and at least one flange extending radially from said elongated rotatable member; at least one other elongated framing element; at least one opening on said other elongated framing element, said opening being shaped to receive said key; wherein said framing elements are arranged to form said array and said key and said opening are used to engage said framing elements by inserting said key into said opening and rotating said key; and wherein said modular storage rack is assembled in a configuration to maximize storage capacity within said shipping container.
 5. A shipping container storage system comprising: a modular array comprising: a plurality of elongated beams, each beam having a pair of opposed ends, each end having a locking hole; a plurality of coupler blocks, each of which has a plurality of external faces, each face having an aperture for receiving an end of a beam, and each aperture having associated therewith a pin retaining hole and a locking mechanism associated with each aperture for releaseably locking the received end of a beam therein, said locking mechanism comprising a retaining pin which is removably insertable within said pin retaining hole, said retaining pin passing through the locking hole of the received end; an wherein said modular array is assembled in a configuration to maximize storage capacity within said shipping container. 